Paper box



R. A. DE FEO July 25, 1961 PAPER BOX Filed Jan. 15, 1959 3 I. am 8. s

RICHARD A. De FEO MAW ATTORNEY 2,993,632 PAPER BOX "Richard A. De Feo, 910 Greenwich St., Philadelphia 47, Pa. Filed Jan. 15, 1959, Set. No. 787,048 9 Claims. ('Cl. 22927) The present invention relates to a paper box, and more particularly to an assembly of paper boxes formed in a continuous web.

Heretofore paper boxes were made from a blank of stiff paper, such as cardboard, whichwas folded to the desired shape and the edges secured together by an adhesive. Thus, each box was individually formed from a separate paper blank. This process of individually forming each box is a time consuming process, and is therefore relatively expensive. Also, the completed paper boxes take up a considerable amount of space both for storage and shipping.

In the use .of such boxes, the boxes must each be individually handled to fill the boxes. This is true whether the boxes are hand filled, or whether the boxes are placed on a conveyor belt for automatic filling. The individual handling of the boxes is a time consuming process which adds to the cost of the article being packaged. Prior boxes have lacked the option of providing the same box available in both multiple and indivdual units.

It is an object of the present invention to provide a novel paper box.

It is another object of the present invention to provide an assembly of paper boxes in the form of a continuous web.

It is still another object of the present invention to provide an integral assembly of paper boxes which can be folded flat for easy storage and shipment.

It is a further object of the present invention to provide an integral assembly of paper boxes which facilitates the assembling, filling and distribution of the boxes.

. It is another object of the present invention to provide a novel way for multiple packaging with the option of the combination in number of units.

It is another object of the present invention to provide novel shapes and forms in boxes.

Other objects will appear hereinafter. a

For the purpose of illustrating the invention there is shown in the drawings a form which is presently preferred; it being understood, however, that this invention is not limited to the precise arrangements and instrumentalities shown.

FIGURE 1 is a perspective view, partially broken away, of the assembly of paper boxes of the present invention.

FIGURE 2 is a perspective view, partially broken away, looking in the direction of arrows 22 of FIGURE 1, and showing the bottom end of one of the boxes of the assembly of the present invention.

FIGURE 3 is a perspective view, partly broken away, of the assembly of paper boxes of the present invention with the boxes completely formed.

FIGURE 4 is an enlarged perspective view of a portion of the assembly of paper boxes of the present invention.

FIGURE 5 is a perspective view illustrating the manner of cutting apart the assembly of paper boxes of the present invention into the individual boxes.

Referring initially to FIGURE 1, the continuous web assembly of paper boxes of the present invention is generally designated as 10. Assembly is made from two continuous length sheets 12 and 14 of stiff paper, such as cardboard.

Sheet 12 is transversely folded adjacent its end along fold line 16 to form a narrow securement flap 18, Lou- U ed $tat P t nt 9 e 2,993,632 Ice Patented July 25,1961

gitudinally spaced from the fold line 16 a distance equal to the desired depth of the boxto be formed, sheet 12 is folded transversely along fold line 20 to extend in the same direction and substantially parallel to the securement flap 18. The portion of sheet 12 between fold'line 16 and fold vline 20 comprises one side 22a of the box 24a. Spaced longitudinally from the fold line 20 a distance equal to the width of two boxes, sheet 12 is folded along fold line 26 to extend across the side 22a of box 24a. The portion of sheet 12 between fold lines 20 and 26 comprises the back faces 28a and 28b of the boxes 24a and 24b respectively. Spaced longitudinally from the fold line 26 and a distance equal to the length of side 22a of box 24a, sheet 12 is transversely folded along fold line 30 to extend back under the back face 28b of box 24b. The portion of sheet 12 between fold line 26 and fold line 30 comprises the side 32b of box 24b. At a distance from fold line 30 equal to the width of securement flap 18, sheet 12 is folded back upon itself to provide a narrow flap 34 having a base 36. Base 36 is extended for a distance equal to twice the width of flap 34, and the sheet 12 is folded back over the base 36 to the side 32b of box 24b. Thus, another flap 38 of the same width as flap 34 is provided over base 36. The flaps 34 and 38 are bonded to the base 36 by an adhesive. From the flap 38, sheet 12 is folded through the same cycle of folds as prevously described to provide the side 22c and back face 280 of box 24c, and the back face 28d and side 32d of box24d. At the end of side 32d of box 24d, sheet 12 is folded to provide a narrow flap 40 having a base 42. As shown in FIGURE 1, base 42 extends a distance greater than twice the Width of the flap 40. Sheet 12 is then folded back over base 42 to provide a narrow flap 44of a width the same as the Width of flap 40. Flaps 40 and 44 are bonded to the base 42 by an adhesive. From the flap 44, sheet 12 is folded'through the same cycle of folds as previously described to form side 22c and back face 28s of box 24c and so on until the end of the sheet 12. The extra width of base 42 spaces the side 22c of box 24a from the side 32d of box 24d for reasons which will be explained later.

The end of sheet 14 extends under securement flap 18 and along the fold line 16 of sheet 12. Securement flap 18 is bonded to the sheet 14 by means of an adhesive. At a distance from the end of sheet 14 equal to the width of back face 28a of box 24a, sheet 14 is folded along fold line 46 to extend across the side 22a of box 24a. The

portion of sheet 14 between fold line 46 and the end of row flap 52 having a base 54. Base 54 has a width equal to twice the width of the flap 52. Sheet 14 is then folded back along the base 54 to provide a narrow flap 56. Flaps 52 and 56 are bonded to the base 54 by an adhesive.

From' the end of flap 56 sheet 14 is folded to extend across the side 32a of box 24a so as to provide the side 2212 of box 24b. From the end of side 22b of box 2412, sheet 14 is folded to extend across the back faces 28b and 280 of boxes 24b and 240 respectively, so as to provide the front faces 48b and 480 of the boxes 24b and 24c. From the end of front face 48c of box 240, sheet 14 is folded through the same cycle of folds previously described to provide the side 32c of box 24c, narrow flap 58, base 60, narrow flap 62, side 22d and front face 48d of box 24d, front face 48c and side 32e of box 24c, and

5 so on until the end of sheet 14. Itshouldbenoted that since the base 42 on sheet 12 is wider than the combined Widths of narrow flaps '40 and 44, the portion of sheet 14 which forms the front faces 48d and 48e should be similarly wider than the combined widths of back faces 28d and 282.

Base 36 of sheet 12 is bonded to the inner surface of sheet 14' by an adhesive, with the center of the base 36 extending along the dividing line between the front face 48b of box 24b and the front face 48:: of box 240. Base 42 is similarly bonded to the sheet 14 with the center line of base 42 extending, along the dividing line between .front face 48d of box 24d and front face 48a of box 24a. Bases 5'4 and 60 of sheet 14 are bonded to the inner surface of the sheet 12 With the center of base 54 extending along the dividing line between the back face 28a of box 48a and back face 28b of box 24b, and the center line of base 60 extending along the dividing line between back faces 28c and 28d of boxes 24c and 24d. Thus, the two folded sheets 12 and 14' are secured together to form a plurality of boxes connected together in a continuous web.

As shown with regard to box 24b, the back face 28b has a cover flap 64 integral with its top edge. Cover flap 64 is adapted to be folded to extend across the top end of the box 24b. A tuck-in flap 66 is integral with the front end of cover flap 64, and is folded so that it can be inserted into box 24b along the inner surface of the front face 48b. The side edges of the tuck-in flap 66 may be cut on a bias so that they are angled toward each other. Thetop edge of the narrow flap 34 and the base 36 may be cut on a bias to mate with the side edge of the tuck-in flap 66. This permits the tuck-in flap 66 to lie fiat against the front face 48b of the box 24]). Each of the sides 22b and 32b of the box 24b has a side flap 68 integral with its top edge. Side flaps 68 are adapted to be folded across the top end of the box 24b beneath the cover flap 64. The narrow flap 34 may be cut or set back along other lines so as to facilitate insertion of the flaps 68 and 66.

In place of the flap construction shown in the drawings, .a notched flap 66 may be provided with the locking of the flap 66 being achieved by engagement with the side flaps 68.

As shownin FIGURE 2, the back face 28b and front face 48b of box 24b each has a bottom flap 70 integral With its bottom edge. Bottom flaps 70 are adapted to be folded across the bottom end of the box 2412. Each of the sides 22b and 32b of box 24b has a bottom side flap 72 integral with its bottom edge. Bottom side flaps 72 are adapted to be folded across the bottom end of box 24b beneath the bottom flaps 70.

For the sake of greater clarity of the drawing, only box 24b is shown as having a top cover 64, side flaps 68 and 72, and bottom flaps 70. However, it should be understood that each of the boxes is provided with similar means for covering the bottom and top ends of the boxes.

The web assembly of boxes can be folded flat for ease of storage and shipping. Box 24a is flattened by swinging the front face 48a and side 32a away from the box 2411' and flat against the back face 28a and side 220. Box 24b is flattened by swinging the front face 48b and side 22b away from the box 48a and flat against the back face 28b and side 32b. Each of the other boxes along the web assembly 10- is flattened in the same manner. With all of the boxes of the web assembly 10 flattened, the web assembly 10 can be rolled-up as shown in FIG- URE 5. The roll of boxes takes up a minimum amount of space so that the boxes can be easily stored and shipped.

As the boxes are required for filling, the web assembly of boxes 10 is unrolledyand the boxes are cut apart. The boxes are cut apart by cutting transversely across the web assembly 10 along the mid point of the various bases and between the adjacent sides of adjacent boxes. Thus, thebox 24a is cut from the box 24b by cutting along the mid point of base 54 and between the side 32a of box 24a and the side 22b of box 24b. Sheets 12 and 14 may be provided with transverse indicia lines 74 on their outer surfaces which are properly positioned to indicate the proper place for cutting the boxes apart. Indieia lines 74 may be lines of perforations to facilitate cutting the boxes apart. Additional indicia lines 74a (see FIGURE 3) may be provided at right angles to indicia lines 74 as along the axial center line, so as to enable each of the boxes to be cut in half.

FIGURE 5 shows one method of cutting the boxes apart. The rolled web assembly of boxes 10 is unrolled across the surface of a cutting anvil 76. With the line of separation between two adjacent boxes positioned over an edge of the anvil 76, a cutting knife 78 is brought down along the line of separation to cut the boxes apart. The boxes may be cut from the web assembly 10 one at a time, or may be cut apart in groups of two or more. FIGURE 5 shows three boxes being cut from the Web assembly 10. If it is found desirable to separate the Web assembly 10 in groups of two or more boxes, the web assembly 10 may be provided with special indicia to indicate each such group. The extra wide base 42 which separates the sides 32d and 22e of adjacent boxes 24d and 24:: provides such an indication. Thus, if the web assembly 10 is to be separated into groups of four boxes, an extra wide base 42 may be provided after each fourth box. The extra wide base 42 is clearly visible so as to provide an indication as to where to separate the boxes, and also provides a handle for each group of boxes.

After the individual boxes, or group of boxes, have been separated from the web assembly 10, the boxes are unfolded. The side bottom flaps 72 are then folded across the bottom end of the boxes, and the bottom flaps 70 are folded across the side bottom flaps 72. The bottom flaps 70 are secured to the side bottom flaps 72 by an adhesive or the like to enclose the bottom of the boxes. The boxes are then ready to be filled with the objects or materials to be packaged. FIGURE 3 shows the two boxes 24a and 24b completely assembled and ready to be filled, but still connected together.

The use of the boxes of the present invention in conneoted groups of two or more greatly facilitates the filling of the boxes. By using. connected groups of the boxes, the group of boxes can be handled as a single unit so as to eliminate the individual handling of the boxes. This, greatly speeds up the handling operation, particularly when the boxes are being fed into an automatic filling machine. Also, the connected boxes are maintained in uniform relation so as to facilitate filling the boxes. When the boxes are filled, they can be cut apart in the manner previously described.

The box constructions of the present invention permit selection of desired numbers of boxes from a group facilitating handling and shipping of packaged units.

The web assembly of paper boxes 10 of the present invention has been described with regard to the forming of rectangular boxes. However, it is to be understood that any other desired shape of box, such as circular, triangular, hexagonal, or any other polygonal shape, can be formed inthe same manner.

The present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof and, accordingly, reference should be made to the. appended claims, rather than to the foregoing specification as indicating the scope of the invention;

I claim:

1. A web assembly of paper boxes comprising two elongated sheets of paper, each of said sheets being folded along'longitudirially spaced, transverse fold lines to form a continuous uninterrupted face for two boxes and a side: of each of the two boxes, said faces on each sheet being overlapped for a distance equal to the width of one box, said sheets being secured together to form a plurality of integrally connected boxes, the connection be- 5 tween each of said boxes permitting the boxes to be separated by cutting thereacross.

2. A web assembly of paper boxes comprising two elongated sheets of paper, each of said sheets being folded along longitudinally spaced, transverse fold lines to form a continuous uninterrupted face for two boxes and a side of each of the two boxes, said faces on each sheet being overlapped for a distance equal to the width of one box, said sheets being secured together to form a plurality of integrally connected boxes with the connection between said sheets also forming the connections between said boxes, said assembly being adapted to be separated into the individual boxes by cutting across the connections between said boxes.

3. A web assembly of paper boxes comprising two elongated sheets of paper, each of said sheets being folded along longitudinally spaced, transverse fold lines to form a continuous uninterrupted face for two boxes and a side of each of said two boxes, said faces on each sheet being overlapped for a distance equal to the width of one box, 2

each of said sheets having a separate base portion between the adjacent sides of each of the adjacent boxes, said base portions of each of said sheets being secured to the other sheet to form a plurality of integrally connected boxes, said assembly being adapted to be sep- 2 arated into the individual boxes by cutting across the base portions and between the adjacent sides of adjacent boxes.

4. A web assembly of boxes in accordance with claim 3 in which the portion of said sheets at each side of each of said base portions is folded back across the respective base portion to form a narrow flap, each of said narrow flaps connecting a side of a box to a base portion, and each of said narrow flaps being secured across its entire width to its respective base portion.

5. A web assembly of paper boxes comprising two elongated sheets of paper, each of said sheets being folded along longitudinally spaced, transverse fold lines to form along the entire length of the sheet an alternating sequence of a pair of box faces in integral side-by-side aligned relation and a pair of overlapping, connected box sides, the sides of each of the pairs of sides being connected by a base portion, the base portions of each of said sheets being secured to the other sheet with each 45 of the base portions extending along the junction of the faces of a pair of box faces on the other sheet to form a plurality of integrally connected boxes, said assembly being adapted to be separated into the individual boxes by cutting across the base portions and between the sides 50 of the pairs of box sides.

6. A web assembly of boxes in accordance with claim 5 including a separate narrow flap connected between each of the box sides and its base portion, each of said flaps extending across its respective base portion and 55 a first box side extending from the flap, at the end of 0 said first box side said sheet being folded to extend across and in the same direction as said narrow flap, at a distance spaced from said first box side equal to the width of two boxes faces said sheet being folded to extend across said box side to form a second box side, at the end of said second box side said sheet being folded to extend back across said box faces to form a second narrow flap, at the end of said second narrow flap said sheet being folded back under said second narrow flap to form a base which is wider than said second narrow flap, at the end of said base said sheet being folded back over said base to form a third narrow flap, at the end of said third narrow flap said sheet being folded to extend across said box sides to form a third box side, said first sheet being folded at spaced intervals from said third box side to form alternating sequences of pairs of box faces and pairs of box sides with the box sides having narrow flaps which are connected by bases; and a second sheet of paper, said second sheet having one end extending beneath and secured to the first narrow flap of said first sheet, at a distance from said one end equal to the width of a box face said second sheet being folded to extend across the box sides of said first sheet to form a first box side, at the end of said first box side said second sheet being folded to extend back across said box face to form a first narrow flap, at the end of said first narrow flap said second sheet being folded back across said first flap to form a base which is wider than said narrow flap, at the end of said base said second sheet being folded back across said base to form a second narrow flap, at the end of said second narrow flap said second sheet being folded to extend across said first box side to form a second box side, from said second box side said second sheet being folded at spaced intervals to form alternating sequences of pairs of box faces and pairs of box sides with the box sides having narrow flaps which are connected by bases; each of the bases of each of said sheets being secured to the other sheet along the junction of a pair of box faces to form a plurality of integrally connected boxes, said assembly being adapted to be separated into the individual boxes by cutting across the bases and between adjacent sides of adjacent boxes.

8. A web assembly of boxes in accordance with claim 7 in which each of said bases is secured across its entire width to the other sheet, and each of said narrow flaps is secured across its entire width to its respective base.

9. A web assembly of boxes in accordance with claim 8 in which each of the boxes of the assembly has cover flaps integral with the ends of the faces and sides of the boxes, said cover flaps being foldable across the ends of the boxes.

References Cited in the file of this patent UNITED STATES PATENTS 1,874,945 Ferguson Aug. 30, 1932 1,998,147 Stegman Apr. 16, 1935 2,710,130 Grecco June 7, 1955 2,771,234 Hultin Nov. 20, 1956 2,772,610 Arneson Dec. 4, 1956 2,783,692 Bolding Mar. 5, 1957 2,845,215 Vogt July 29, 1958 

